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REMOVAL AND INSTALLATION
 
 
Pre-removal and Post-installation Operation
 
 
Removal steps
1.Purge pipe and hose assembly
2.Purge hose
3.Hose clip
4.Radiator upper hose connection
5.Hose clip
6.Radiator lower hose connection
7.Water inlet fitting (Refer to THERMOSTAT REMOVAL AND INSTALLATION)
8.EGR temperature sensor
9.Gasket
10.EGR valve pipe
11.EGR valve pipe gasket
12.EGR inlet pipe
13.EGR valve pipe gasket
14.Engine coolant temperature sensor
•Control wiring harness connection
15.Water hose A
16.Water hose B
17.Water hose C
18.Water hose D
19.Water pipe
20.Water pipe gasket
21.Heater piping hose connection
22.Water return hose
23.Water return pipe
•Water pump drive belt (Refer to ENGINE MECHANICALCRANKSHAFT PULLEY REMOVAL AND INSTALLATION)
•Water pump (Refer to WATER PUMP REMOVAL AND INSTALLATION)
24.Water pump inlet pipe
25.O-ring
26.Water pump inlet pipe gasket
 
 
REMOVAL SERVICE POINTS
 
 
<<A>> HOSE CLIP/RADIATOR HOSE DISCONNECTION
1. Make mating marks on the radiator upper hose and the hose clip as shown to install them in the original position.
2. Break off the tip of hose clip claw and spread out the hose clip, then disconnect the radiator upper hose.
noteIf there is a hose clip claw, the hose clip cannot spread to capacity because the claw contacts the hose clip.
 
 
 
<<B>> EGR TEMPERATURE SENSOR REMOVAL
Use special tool EGR temperature sensor wrench (MB992692) to remove the EGR temperature sensor.
 
 
 
<<C>> EGR VALVE PIPE / EGR VALVE PIPE GASKET / EGR INLET PIPE REMOVAL
1. Remove the connection on thermostat case side of water hose D to secure work space, disconnect the connector on the engine sub harness at the position shown in the figure, and remove the connector clamp from the bracket.
2. After removing the ground wire and clamp, remove the EGR valve pipe, EGR valve pipe gasket, and EGR inlet pipe.
 
 
 
<<D>> ENGINE COOLANT TEMPERATURE SENSOR REMOVAL
Use special tool water temperature sensor wrench (MB992042) to remove the engine coolant temperature sensor.
 
 
 
 
INSTALLATION SERVICE POINTS
 
 
>>A<< WATER PUMP INLET PIPE GASKET INSTALLATION
Install the gasket as its protrusion is in the direction shown.
 
 
 
>>B<< O-RING INSTALLATION
cautionAvoid adhesion of engine oil or grease to the O-ring.
Fit the O-ring in the water pipe groove, wet the O-ring circumference or the thermostat case mounting area inner wall, and then insert the O-ring.
 
 
 
>>C<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION
1. Apply the specified sealant to the engine coolant temperature sensor thread.
Specified sealant: ThreeBond 1324N or equivalent
2. Use special tool water temperature sensor wrench (MB992042) to tighten the engine coolant temperature sensor to the specified torque.
Tightening torque: 30 ± 9 N·m (22 ± 6 ft-lb)
 
 
 
>>D<< EGR INLET PIPE / EGR VALVE PIPE GASKET / EGR VALVE PIPE INSTALLATION
Mount each part in the following order.
1. Temporarily tighten each part so that the protrusions of each gasket and the EGR inlet pipe are positioned as shown in the figure.
2. Tighten each part to the specified torque.
Tightening torque: 20 ± 2 N·m (15 ± 1 ft-lb)
3. Tighten the clamp to the specified torque.
Tightening torque: 10 ± 2 N·m (89 ± 17 in-lb)
4. Tighten the ground wire.
 
 
 
>>E<< EGR TEMPERATURE SENSOR INSTALLATION
Use the special tool EGR temperature sensor wrench (MB992692) to tighten the EGR temperature sensor to the specified torque.
Tightening torque: 21 ± 2 N·m (15.5 ± 1.4 ft-lb)
 
 
 
>>F<< RADIATOR HOSE/HOSE CLIP CONNECTION
cautionNever reuse the hose clip whose claw is broken off to prevent the rusting.
1. Make mating mark on a new hose clip in the same position as the remove one.
2. Insert the radiator upper hose until the protrusion of the water outlet fitting.
3. Align the mating marks on the radiator upper hose and hose clip.
4. Remove the hose clip claw and shorten the hose clip, then install the radiator upper hose.